Conveyor module, conveyor assembly, and method of installing a conveyor assembly

ABSTRACT

A conveyor module ( 1 ), adapted to be releasably attached to at least one other conveyor module ( 1 ) to form a conveyor assembly ( 15 ). Each conveyor module ( 1 ) includes a substantially longitudinal main frame ( 4 ), said main frame ( 4 ) being adjustable in between a first position (FIG.  3 ), in which said module ( 1 ) is compacted for transportation, and, a second position (FIG.  4 ), in which said module ( 1 ) is expanded for conveyor operation. A plurality of support legs ( 17 ) is provided to support said conveyor module ( 1 ) upon a substrate surface, each support leg being adjustable to facilitate adjustable alignment of said module ( 1 ). Conveyor componentry ( 12 ) is housed substantially within said main frame ( 1 ). The conveyor module ( 1 ) is preferably formed from or built to standardised shipping container (ISO) specifications.

BACKGROUND OF INVENTION

The present invention relates to a modular conveyor system, and inparticular, to a conveyor module and associated support frame which maybe easily transported and installed with other such conveyor modules andframes to form a conveyor assembly.

DESCRIPTION OF THE PRIOR ART

The reference in this specification to any prior publication (orinformation derived from it), or to any matter which is known, is not,and should not be taken as, an acknowledgement or admission or any formof suggestion that prior publication (or information derived from it) orknown matter forms part of the common general knowledge in the field ofendeavour to which this specification relates.

Conveyor belt systems used to transport minerals from mine sites areoften needed in remote locations where installation and maintenance ofconveyors may be challenging. Installation of conveyor belt systems isquite often difficult and costly, as significant earthworks may berequired, and, labour may be scarce and/or skilled. Furthermore, afteroperation of such a mine ceases, or the location of mineral extractionchanges, conveyor belt assemblies may typically be required to bede-mobilized. However, such known conveyor systems are typically notreadily relocatable.

SUMMARY OF THE INVENTION

The present invention seeks to overcome at least some of thedisadvantages of the prior art.

The present invention seeks to provide a conveyor module which may beutilized with other such conveyor modules to form a conveyor assemblywhich is, due to its modular form, is more easily and less expensivelyinstalled than the aforementioned prior art conveyor systems.

The present invention seeks to provide a modular conveyor system whichis optionally reusable and relocatable to a different geographicalposition when the conveyor system is no longer required at the originallocation.

The present invention also seeks to provide a modular conveyor systemwhich is dimensioned in a standardized modular size in the form of anintermodal shipping container, ISO container or other like container,and such that it is compatible to be readily transported via ship, trainor truck.

The present invention also seeks to provide a conveyor system which maybe prefabricated then transported to the location ready for use andalready incorporating many/all of the conveyor componentry therein suchthat it may then be commissioned by relatively simple non-specialistpersonnel ready for use. Likewise, the system may be decommissioned withnon-specialized labour and tools and then removed to an alternativelocation, if required.

In one broad form, the present invention provides a conveyor module,adapted to be releasably attached to at least one other conveyor moduleto form a conveyor assembly, said conveyor module including:

a substantially longitudinal main frame, said main frame beingadjustable between:

a first position, in which said module is compacted for transportation;and,

a second position, in which said module is expanded for conveyoroperation;

a plurality of support legs to support said conveyor module upon asubstrate surface, each support leg being adjustable to facilitateadjustable alignment of said module; and

conveyor componentry housed substantially within said main frame, saidconveyor componentry including any one or combination of:

a conveyor belt;

a conveyor belt support structure;

a conveyor belt idler;

an adjustable height/width conveyor belt support post;

a boot end;

a tail end;

a loop take up; and,

a loading hopper.

Preferably, said extension is formed from or built to standardisedshipping container (ISO) specifications, such that, in its firstposition, said module is compatible with conventional intermodal freighttransportation modes including by shipping, rail, road or othertransportation methods.

Also preferably, said main frame includes a roof, wherein said roof ismovable between:

a first position, wherein said roof is housed substantially within saidmain frame for transportation; and,

a second position, wherein said roof extends at least partially outwardsof said main frame for conveyor operation.

Preferably, said roof is movable substantially vertically and/or isadapted to substantially horizontally extend at least partially outwardsof an end of said main frame by pivoting, folding or the like.

Also preferably, said conveyor componentry includes adjustable mountingsto adjustably support said conveyor belt support structure and idlerarrangement, said mountings allowing adjustable movement of saidconveyor belt support structure between:

a first position, in which said conveyor componentry is compactly storedwhen said module is compacted for transportation; and,

a second position, in which said conveyor componentry is rotated orotherwise unfolded or the like from said stored position to anoperational position.

Preferably, when said conveyor belt support structure is in saidsecond/unfolded position, said conveyor components may be furtheradjusted horizontally and/or vertically.

Preferably, further vertical and/or horizontal adjustment is facilitatedusing one or more vertical and/or horizontal slots, respectively.

Also preferably, each support leg is height adjustable to facilitatelevelling/adjustment of said module.

Preferably, each support leg includes a twist lock fitting to facilitatefixing and release of said module to said support post.

The present invention also provides a plurality of conveyor modules ashereinbefore described.

Preferably, each support leg is adjustable so as to permit angulardisplacement or articulation between adjacent conveyor modules.

In a further broad form the present invention provides a method ofinstalling a conveyor assembly, including:

positioning one or more support legs in spaced apart location on asubstrate surface;

and, spanning a conveyor module between said spaced apart support legs.

Preferably, the method further includes interlocking said conveyormodule to said support leg.

Preferably, the method further includes elevating an adjustable heightroof on said main frame from a transportation position to conveyoroperation position.

Preferably, the method further includes extending a roof, from said mainframe, from a first position wherein said roof is substantially housedwithin or proximal to said main frame, to a second position, whereinsaid roof extends at least partly outwards of said main frame.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thefollowing detailed description of preferred but non limiting embodimentsthereof, described in connection with the accompanying drawings wherein:

FIG. 1 illustrates an isometric view of the conveyor moduleincorporating conveyor componentry in accordance with the presentinvention;

FIG. 2 illustrates an isometric view of two conveyor modules in spacedapart locations to form a conveyor assembly in accordance with thepresent invention;

FIG. 3 illustrates, in FIGS. 3(a), 3(b) and 3(c) isometric, sideelevation and end elevation views, respectively, of the conveyor modulein accordance with the present invention in a first position with itsroof lowered and compacted for transportation;

FIG. 4 illustrates, in FIGS. 4(a), 4(b) and 4(c), the conveyor module ina second position where it is expanded with the roof raised for conveyoroperation;

FIG. 5 illustrates in FIGS. 5(a) and 5(b) respectively, top and bottomviews of the conveyor module in accordance with the present invention;

FIG. 6 illustrates an expanded view of the end portion of the conveyormodule of FIG. 1, but with the extension frame extending at leastpartially out the end of the substantially longitudinal main frame;

FIG. 7 illustrates, in FIG. 7(a), an isometric view of the support framein accordance with the present invention, which may be used to interlinktwo spaced apart conveyor module, and, in FIG. 7(b), an expandedisometric view of the support post 17 of FIG. 7(a);

FIG. 8 illustrates some additional views of the support frame shown inFIG. 7;

FIG. 9 illustrates an isometric view of a pair of conveyor modulessupported on either end of the support frame shown in FIG. 7;

FIG. 10 illustrates an elevational view of some of the main componentsof some of the support frame and modules that are shown in FIG. 9, withthe conveyor componentry in the operating position;

FIG. 11 illustrates how the conveyor componentry may be stowed fortransport;

FIG. 12 illustrates transport and operational positions of supportframes with optional fold down conveyor support structures thereon;

FIG. 13 illustrates in FIGS. 13(a) and 13(b) a typical means ofinterconnecting the support frames with a conveyor module, showing atwist lock fitting arrangement;

FIG. 14 shows, in FIGS. 14(a) and 14(b) a removable roof configurationfor the conveyor module in accordance with the present invention;

FIG. 15 illustrates an end view of the arrangement shown in FIG. 14,showing a double pin connection for securing the roof, this figure alsoillustrating a slide out roof;

FIG. 16 illustrates a split roof arrangement for the conveyor modules inaccordance with the present invention;

FIG. 17 illustrates, in FIGS. 17(a) and 17(b) a tarpaulin roof optionfor the conveyor module of the present invention;

FIG. 18 illustrates a floor mounted “H” frame support structure for theconveyor components in accordance with the present invention;

FIG. 19 illustrates, in FIGS. 19(a), 19(b) and 19(c), differentpositions of support posts in the conveyor module to suit different beltwidths, FIG. 19 showing these support post position for a wide beltwidth, FIG. 19(b) showing the support post position for a mid belt widthand FIG. 19(c) showing a support post position for as narrow belt width;

FIG. 20 illustrates an adjustable support mounting to facilitatehorizontal and vertical adjustment of the conveyor components relativeto the support post;

FIG. 21 illustrates operational and transport position of a retractablelanyard wire support system which may be incorporated in the conveyormodule of the present invention;

FIG. 22 illustrates a structure mounted lanyard wire support which maybe incorporated in the conveyor module of the present invention;

FIG. 23 illustrates in FIG. 23(a) transport, in transit, and operationalpositions of a drop down cable tray which may be incorporated in theconveyor module of the present invention, and, in FIG. 23(b) a roofmounted cable tray option;

FIG. 24 illustrates a walkway support beam arrangement which may beincorporated in the conveyor module of the present invention;

FIG. 25 illustrates an alternative to the support frame;

FIG. 26 illustrates yet an alternative support frame to that shown inFIG. 7, but which may also be used to interlink two spaced apartconveyor modules;

FIG. 27 illustrates framework of a modular conveyor structure,dimensioned to be compatible with an intermodal shipping container, FIG.27(a) showing the module without the conveyor componentry includedtherein and, FIG. 27(b) showing the module with conveyor idlers therein;

FIG. 28 illustrates support legs which may support the module, FIG.28(a) showing an isometric view thereof, FIG. 28(b) showing across-sectional view of the support leg in the operational position, andFIG. 28(c) showing a cross-sectional elevational view of the leg in thefolded, retracted or transport position;

FIG. 29 illustrates views of a conveyor module in which the internalcomponentry is installed in an angular or asymmetric manner if needed tosuit a horizontal curve, so as to facilitate appropriate conveyance ofmaterial thereon around the curve or the like, FIG. 29(a) showing an endview of a conveyor module, and FIG. 29(b) showing an alternative endview of a conveyor assembly;

FIG. 30 illustrates views of a connection arm, adapted to secure orinterconnect adjacent modules, FIG. 30(a) showing the arm itself, andFIG. 30(b) showing it installed between a pair of modules;

FIG. 31 illustrates how a module may be elevated from a substratesurface on elongated, elevated support legs;

FIG. 32 illustrates how a loading hopper may be positioned over aconveyor module; and

FIG. 33 illustrates how a module may be configured so that a roboticidler changing machine may travel along the top of the conveyor modules.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Throughout the drawings, like numerals were used to identify similarfeatures, except where expressly otherwise indicated.

It should be appreciated also that whilst particular embodiments of theinvention, which relate to any one or combination of a conveyor module,a support frame, and a conveyor assembly, together with a method oftransporting, installing and operating a conveyor assembly are hereindescribed and shown, these are for exemplary purposes only. Theinvention should not be limited to these specific embodiments. All suchvariations and modifications which become apparent to person skilled inthe art should be considered to be encompassed within the scope of thisinvention.

As shown in FIG. 1, the conveyor module, generally designated by thenumeral 1, may typically be formed from, or built to be similar to, ashipping container which houses pre-assembled conveyor components.

Persons skilled in the art will readily appreciate that a shippingcontainer has a standardized size which is dimensioned such that it canreadily fit on a ship, train, truck, or other mode of transport, and bestacked, along with like containers to store and transport goodsdomestically and internationally. Such containers are known under anumber of names, such as simply “container”, cargo or freight container,ISO container, shipping, or ocean container, etc. When referring to the“module” of the present invention, it should be understood that the“module” of the present invention may, in its preferred embodiment, bedimensioned to be equivalent, or at least compatible with, such astandardized ISO intermodal shipping container.

The conveyor assembly of the present invention, is typically formed of aplurality of conveyor idler structures provided in spaced apart locationrelative to each other. These conveyor idler structures collectivelysupport a conveyor belt, and, are operated by appropriate drive means,etc.

The conveyor module 1 according to present invention shown in FIG. 1,includes a basic module structure being formed of a substantiallylongitudinal main frame portion 4. The ends 5 and 6 of thelongitudinal-shaped module 1 may be substantially open, such that themodule 1 may be positioned adjacent similar conveyor modules 1, tothereby effectively form a conveyor assembly of any desired length.

The embodiment illustrated in FIG. 1 shows, a preferred arrangement of amodule 1 having a floor surface 7, a roof surface 8, and, substantiallyopen side walls 9 and 10. A plurality of conveyor idler structures 3 areprovided in spaced apart relationship within the module 1. As will beunderstood by a person skilled in the art, such a structure may provideprotection to the conveyor components housed therein from weather, dustand environmental effects, whilst having at least partly open oropenable side walls 9 and 10 to allow for visual inspection and/ormaintenance access to the conveyor structure.

FIG. 2 illustrates how two such conveyor modules 1, as shown in FIG. 1,may typically be interconnected via a support frame 11 to effectivelyjoin the conveyor modules 1 such that they can function as a compositeconveyor assembly 15.

Whilst further explanation will be provided hereafter, FIG. 2illustrates how idler rollers 12 may extend outwardly from the ends 5and 6 of the conveyor module 1 to a position above an interconnectingsupport frame 11, and, how an extension roof 13 may be adapted to extendfrom one or both ends of the spaced apart conveyor modules 1. Prior togoing into the details of how the modules 1 are positioned/installed andthen expanded to form the conveyor assembly 15, details of the conveyormodule 1 will be firstly illustrated with reference to FIGS. 3 to 6.

In FIG. 3, is shown various views of the conveyor module 1 in a firstposition wherein the roof 8 is stowed in a transport position forcompact transportation of the conveyor module 1. FIG. 3(a) illustratesan isometric view of this transport position of conveyor module, whilstFIG. 3(b) illustrates a side elevation view, and, FIG. 3(c) illustratesan end view.

Referring now to FIG. 4, which shows similar views to FIG. 3, theconveyor module 1 is shown with the roof 8 raised to an expanded oroperational position. FIG. 4(a) illustrates an isometric view with theroof raised in this operational position, whilst FIG. 4(b) illustratesside elevation view with the roof raised, and, FIG. 4(c) shows an endview with the roof raised. It should be noted that in FIGS. 3 and 4, theconveyor componentry is not shown for clearer understanding of the roofpositions.

FIG. 5 illustrates, in FIGS. 5(a) and 5(b), plan and bottom views,respectively of the conveyor module 1 as shown in FIGS. 3 and 4.

Referring now to FIG. 6, the conveyor module 1 is illustrated to betypically formed of a substantial longitudinal main frame 4, and, anextension frame portion 14. As will be understood from FIG. 6, theextension of frame portion 14 may be adapted to slidably extend at leastpartially outwardly of the end of the main frame 4. The extension frameportion 14, which supports conveyor components 12 effectively increasesthe operable length of the conveyor module 1. This facilitatesproductive use of the available space in or from each conveyor module 1,during transportation, whilst thereafter, at the installation location,the extension frame portion 14 may be slid outwards to the operatingposition, such as shown in FIG. 6.

Referring back to FIG. 2, it will be noted that, when two conveyormodules 1 are positioned in spaced apart relationship, the extensionframes 14 of each module 1 may be slid outwardly towards each other. Theadvantage of having these slidable extended frame portions 14 ratherthan simply providing a plurality of conveyor modules adjacent to eachother is that this reduces the number of modules required to be builtand transported. This is particularly advantageous in remote locations.

FIGS. 7(a) and 8 illustrate a preferred embodiment of a support frame 11which may be used in conjunction with the conveyor module 1 to form theconveyor assembly 15 of the present invention. The support frame 11, asshown in FIGS. 7(a) and 8 may be typically formed of metal and may bemade of any desired size. The support frame is adapted to be positionedon a substrate surface, to support modules 1. The ends 16 of the frame11 may optimally be telescopically expandable in width, and, providedwith support posts 17 for engaging with and supporting the conveyormodule 1. As shown in FIG. 7(b), the support posts 17 are preferablyheight adjustable to compensate for an uneven substrate surface and/orto support the support frame 11 in a substantially horizontal manner orany other desired angular disposition.

FIG. 9 illustrates a preferred embodiment of a portion of a conveyorassembly 15, including a pair of conveyor modules 1 supported on eitherend of a support frame 11, and in particular, on the corners of thesupport frame 11 on support posts 17. As will be understood, any numberof conveyor modules 1 and support frames 11 may be interconnected toform a conveyor assembly.

FIG. 10 illustrates a schematic elevational view showing how typicalconveyor components 12 may slide out from the ends of conveyor modules1, above the support frame 11 to the operational position.

FIG. 11 shows the conveyor module 1, with an extendable frame portioncompactly housing the conveyor components 12 within the container module1, in the transportation position.

In FIG. 12 is shown how a support frame 11 may optionally incorporatevarious typical conveyor components thereon. FIG. 12 illustrates boththe transport position, wherein the conveyor components may be pivotallyhinged in a compacted configuration, and, in an operational positionwherein the conveyor components are pivotally rotated from thattransport position to a position for operational use. Thisconfiguration, as will be understood by a person skilled in the art,could be utilized instead of, or in addition to, incorporating the slideout conveyor component structure as previously described and shown, suchas, with reference to FIG. 10.

In FIG. 13(a) is illustrated how a support frame 11 may typically bereleasably engaged to a conveyor module 1. FIG. 13 illustrates a supportleg 17 of the support frame 11 incorporating a twist lock fitting 18.The twist lock fitting 18 enables quick fixing and release of the module1 to or from the support post 17. The configuration shown, having atapered upper end on the twist lock fitting 18, facilitates easyself-location with or in an engagement slot or orifice provided withinthe corner under the bottom of conveyor module 1. A variety ofengagement or locking devices in alternative to the twist lock fitting18 may alternatively be used, as would be readily apparent to personsskilled in the art.

As shown in FIG. 8, the support 11 may optionally be telescopic in formto allow for variation in frame width, so as to facilitate compacttransportation but, allowing it to be expanded in width when desired tobe connected to the conveyor module 1. The support frame 11 preferablyallows for longitudinal movement and articulation between adjacentmodules 1.

As shown in FIG. 13 (b) the support leg 17 may also be height adjustableto assist in leveling of the container modules 1 attached thereto.

A plurality of support frames 11 may typically be positional in pairsback to back with support legs stowed therebetween duringtransportation. This permits efficient transportation of a plurality ofthe support frames/modules in a single transportation exercise, thusensuring cost efficiency.

Alternatively, instead of using the support frames, drop down legs, suchas shown in FIG. 28 (and which will be described hereinafter) may beused to support the conveyor modules 1 on the substrate surface.

A variety of roof structures may alternatively be used on the modules 1.In FIG. 14 is illustrated a configuration of a roof 8 which isadjustable in height and/or is removable. FIG. 14(a) illustrates theadjustable roof 8 in the transportation position, whilst FIG. 14(b)illustrates the roof 8 in the operational position.

FIG. 15 illustrates how the roof 8 may be engaged and secured with theremainder of the main frame 4, the illustrated embodiment showing theuse of a double pin locking arrangement, for improved rigidity.

In FIG. 16 is shown a split roof arrangement, whereby a slide out roof13 may be slid out from each conveyor module 1. The slide out roofportions 13 from two adjacent modules 1 may substantially abut as shownin FIG. 16.

Alternatively, a tarpaulin roof may be provided, such as shown in FIG.17. FIG. 17(a) illustrates a tarpaulin roof in a closed position, whilstFIG. 17(b) shows the tarpaulin roof in the open position. Such a roofmay be provided in locations of less harsh environments, where a moresolid structure may not be required. The tarpaulin roof embodimentadvantageously provides some form of protection from dust etc. ingressto the conveyor whilst enabling easy access during maintenance.

In FIG. 18 is illustrated how typical conveyor components such as aconveyor idler 3 may be supported on the floor 7 of module 1 utilizingan “H” frame support structure. Various means for adjusting the positionof the conveyor components will be described hereafter.

For example, in FIG. 19 is illustrated how idler support posts may bepositioned at different locations to suit different belt widths. FIG.19(a) illustrates the support post to suit a wide belt width, whilstFIG. 19(b) illustrates a support post position to suit a mid belt width,and, FIG. 19(c) illustrates a support post position to suit a narrowbelt width.

To facilitate adjustment the conveyor components 3, various mountingsmay be utilized. FIG. 20 illustrates a mounting 20 which incorporatesone or more horizontal slots 22 and one or more vertical slots 21, toallow for both horizontal and vertical adjustment of the conveyor idler3 or other conveyor components.

Conveyor support brackets can also be supplied in an offset version thatadjusts either side if the structure inbye or outbye to compensate foran out of tolerance condition that affects belt tracking.

As will be understood by persons skilled in the art, various otheroptional features may additionally be provided with conveyor module ofthe present invention. For example, wire supports may be required. Aretractable lanyard wire support 23 is shown in FIG. 21, illustratingboth the operating and transport positions of such a component.

FIG. 22 illustrates a structured mounted lanyard wire support which mayalso optionally be incorporated in the module of the present invention.

FIG. 23(a) illustrates yet another optimal conveyor component, being adrop down cable tray 24, and shows both the transport in transit andoperational positions of the cable tray, and, FIG. 23(b) illustratesroof mounted cable tray option.

FIG. 24 shows a walkway support beam may additionally be incorporated toprovide walkway and maintenance access on any elevated section of theconveyor. The platform support beam may be supplied as a mounting pointfor walkway sections when required.

As will be apparent to persons skilled in the art, conveyor modules 1may be manufactured to house any number of optional conveyor componentstherein and then transported, in a compact manner to the location wherethe conveyor modules are to be installed to form a conveyor assembly 15.To install the conveyor assembly 15 at the installation location,support frames 11 may be firstly placed on the substrate surface. Oncesupport frames 11 are in position, then a conveyor module 1 may bepositioned atop the ends of the support frames 11 and span adjacentlypositioned support frames 11. A twist lock arrangement 18 described inrelation to FIG. 13 may be utilized, so that the module 1 may beeffectively locked to the respective support frame support posts 17.Thereafter, the extension frames 14 may be slid outwardly of the mainframe 4, and any conveyor componentry may then be spaced apart atappropriate positions along the conveyor assembly 15. For example,conveyor idlers 3 which may initially be transported within the mainframe 4 may be slid out on the extension frames 14 to their desiredoperational position such that they are then relatively evenly spacedapart, if so desired, to thereby then support a conveyor belt.

The roof 8 of the modules 1 may be elevated from the transportationposition to the conveyor operational position. If the conveyor assemblyis at some stage later thereafter decommissioned, extension frames 14may be slid back within the main frames 4 to be compactly housed andthereby transported for relocation to another location.

Particular embodiments of the module 1, support frame 11, etc have beenherein described, as have certain optional features thereof, alldirected towards a conveyor module which may be pre-fabricated with allits main components, then transported for installation, along with othersuch modules 1. The modules 1 are typically dimensioned to be compatiblewith the standardized ISO intermodal shipping container dimensions. Themodules may then be quickly and easily transported with existing modesof transportation set up for transporting shipping containers, and thenrapidly commissioned at a location, which may typically be remote.

As shown in FIG. 25, an end of a conveyor module 1 may alternatively beembodied to be supported on a support pad, for example, a support padformed of concrete or like material. The module may be, in thisembodiment, affixed to the support pad in a removable manner byutilizing a bridge clamp connection as shown in FIG. 25. Alternatively,a pre-cast threaded bore casing that allows threaded adjustable legswith twist lock fittings may be used. Other forms of support mayalternatively be used as will be appreciated by persons skilled in theart.

In FIG. 26 is shown an alternative support frame 11 to that previouslydescribed in relation to FIG. 7. This version of the support frame 11incorporates a trestle arrangement which provides the ability to flatpack the frame sides for transport. The sides may then be boltedtogether on site to form a trestle. The four corners of the base mayutilize corner castings which could provide a simple lock in to the bedof a truck, similar to that as is done with shipping containers. Framescould typically be supplied in adjustable height to cater for varyingslope.

FIG. 27 shows yet an alternative embodiment of the invention. Aspreviously described, the conveyor module 1 of the present invention ispreferably formed to be of a standardized size and shape such that itsubstantially conforms with an intermodal shipping container. Theframework of another embodiment of a container module 100 is illustratedin FIG. 27, without the conveyor componentry shown therein, but, with“drop down” support legs 101 shown thereon. The container framework,generally designated by the numeral 100, shows four support legsprovided thereunder 101, and also, shows module connection arms 102 onone end of the framework, the details of which will be describedhereinafter. FIG. 27(b) also illustrates the frame 100, the legs 101 andthe arms 102, but also illustrates idlers 103 positioned within theconveyor module frame 100, at spaced apart locations therein.

In FIG. 28 is detailed a preferred but non-limiting embodiment of suchsupport legs 104, FIG. 28(a) illustrating an isometric view of thesupport leg structure, whilst FIG. 28(b) showing an elevational viewthereof in the operational position, and FIG. 28(c) showing anelevational view thereof in the folded, or retracted position, suitablefor transportation. The embodiment of the support leg shown in FIG. 28shows a plate-like member 105 which is adapted to be supported on asubstrate surface, and which may optionally incorporate an abutmentsurface which is designed to inhibit movement when positioned on thesubstrate surface by means of having raised ribs or the like. Thesupport leg itself 107 is preferably articulated about pivot point 108such that it can move between the operational position as shown in FIG.28(b) and the folded, or retracted position shown in FIG. 28(c) suchthat it may be compactly stored for transportation. A plate at the topof support leg 107, illustrated by the reference numeral 109 may bebolted or otherwise attached to the module 110 as will be appreciated bya person skilled in the art by bolts, pins, or the like.

In FIG. 29 is illustrated how the internal conveyor componentry 115within the module 116 may be angularly positioned therein in anasymmetric manner or the like, so as to take into account desiredcurvature, for instance when the conveyor is intended to convey materialaround a curve or corner. FIG. 29(b) illustrates the modular container116 in an angular disposition supported on support legs 117 and 118above substrate plates 119 and 120 respectively. As will be appreciatedby persons skilled in the art such angular disposition facilitatesappropriate conveyance of the conveyed material on the conveyor, and theextent of angling is variable depending on site specifications, etc.Vertical curves are also possible, in that conveyor is able to go up anddown grades of up to around 10 degrees. Compound curves where angulationin both horizontal and vertical planes is also possible.

In FIG. 30 is illustrated various views of a module connection arm,which is adapted to secure or interconnect adjacent modules.

The connection arm, illustrated by reference numeral 121 may typicallybe pivoted about a pivot point 122 and/or elongated using an extendiblelength arm 123 and incorporate appropriate connection members 124 and125 for securement to a pair of modules 126 and 127 respectively, asillustrated in FIG. 30(b). It will be appreciated that a variety ofdifferent types of connection arms etc. may alternatively be usedutilized.

In FIG. 31 is illustrated an elevated conveyor module, elevated from thesubstrate surface on elongated support legs. The module 130 is shownhaving four elongated legs 131 supported on substrate plates 132. Thelegs 131 may be of adjustable length, if desired, as will be understoodby person skilled in the art.

In FIG. 32 is illustrated how a hopper may be positioned over a conveyormodule. The conveyor module 140 is shown supported on its varioussupport legs 141, and the hopper 142 is shown having its own framework143 to position it over the module. Various other components maylikewise be installed, as desired. The Hopper can alternatively be anintegral part of the conveyor module and bolted directly to structuralelements.

It will be appreciated by persons skilled in the art that the module maybe readily installed by being transported by ship, truck, train or othertransportation modes and then, being appropriately craned into position.

FIG. 33 shows a robotic idler changing machine adapted to travel alongthe top of a conveyor module 1. The robotic idler changing machine isadapted to lift a running conveyor belt with product clear of the idlerrollers. Robotic arms can then remove damaged rollers and replace withnew rollers in a safe manner whilst not disrupting productive time.

It will be appreciated that numerous other variations and modificationswill become apparent to persons skilled in the art. All such variationsand modifications should be considered to fall within the scope of theinvention as broadly hereinbefore described and as hereinafter claimed.

1-15. (canceled)
 16. A conveyor assembly including a plurality ofinterconnected pre-assembled conveyor modules, wherein eachpre-assembled conveyor module comprises: a substantially longitudinalmain frame, which is sized to be of standardised shipping container(ISO) dimensions; a plurality of support legs to support said respectiveconveyor module upon a substrate surface, wherein each support leg isheight adjustable to facilitate levelling adjustment of said respectivemodule; conveyor belt componentry, comprising a plurality of conveyoridlers pre-assembled in spaced-apart arrangement within saidlongitudinal main frame, the conveyor idlers being angularly adjustablewithin the main frame; wherein, the assembly is formed by: transportingthe plurality of said pre-assembled conveyor modules to an installationlocation; interconnecting the plurality of pre-assembled modules inend-to-end relationship atop a substrate surface to thereby form acomposite assembly of any desired length, and adjusting the support legsto thereby adjust alignment comprising angular displacement orarticulation between the modules according to site curves, grades orother sites specifications; and, supporting a conveyor belt collectivelyabout the plurality of conveyor idlers of the interconnected modules,and adjusting the position of said conveyor idlers inside saidinterconnected modules to thereby further compensate for site curves,grades and other site specifications which may affect belt tracking. 17.A conveyor assembly according to claim 16, wherein the main frame ofeach pre-assembled module is adjustable between: a first position, inwhich said module is compacted for transportation; and, a secondposition, in which said module is expanded for conveyor operation.
 18. Aconveyor assembly as claimed in claim 16, wherein said main frame ofeach pre-assembled module includes a roof, wherein the roof is movablebetween: a first position, wherein the roof is housed substantiallywithin the main frame for transportation; and, a second position,wherein the roof extends at least substantially horizontally at leastpartially outwards of the main frame for conveyor operation by pivoting,folding or the like.
 19. A conveyor assembly as claimed in claim 16,wherein the conveyor componentry included in each pre-assembled conveyormodule comprises at least one of: a conveyor belt; a conveyor beltsupport structure; a conveyor belt drive motor; and, an adjustableheight/width conveyor belt support post.
 20. A conveyor assembly asclaimed in claim 18, wherein said roof of each pre-assembled module ismovable substantially vertically and/or is adapted to substantiallyhorizontally extend at least partially outwards of an end of said mainframe by pivoting, folding or the like.
 21. A conveyor assembly asclaimed in claim 16, wherein said conveyor componentry of each modulecomprises adjustable mountings to adjustably support said conveyor beltsupport structure and idler arrangement, said mountings allowingadjustable movement of said conveyor belt support structure between: afirst position, in which said conveyor componentry is compactly storedwhen said module is compacted for transportation; and, a secondposition, in which said conveyor componentry is rotated or otherwiseunfolded or the like from said stored position to an operationalposition.
 22. A conveyor assembly as claimed in claim 21, wherein whensaid conveyor belt support structure of each module is in saidsecond/unfolded position, said conveyor components may be furtheradjusted horizontally and/or vertically.
 23. A conveyor assembly asclaimed in claim 22, wherein said further vertical and/or horizontaladjustment is facilitated using one or more vertical and/or horizontalslots, respectively.
 24. A conveyor assembly as claimed in claim 16,wherein each support leg on each pre-assembled module comprises a twistlock fitting to facilitate fixing and release of said respective moduleto said support post.
 25. A conveyor assembly as claimed in claim 16,wherein said pre-assembled modules are interconnected using a moduleconnection arm.